[WIP] 1965 Ford Mustang

[Alibro]

You don't need a bender, it would only work for two sides anyway, just cut half way through at the fold (on the outside or it won't fold properly) and it will fold nicely. A quick bead of hot metal glue and your done.

[chrskly]

You don't need a bender, it would only work for two sides anyway, just cut half way through at the fold (on the outside or it won't fold properly) and it will fold nicely. A quick bead of hot metal glue and your done.

Gotcha, like scoring cardboard.

[jrbe]

If you're in the US you can check send cut send or OSH cut. Both can bend and are fairly priced.

[chrskly]

If you're in the US you can check send cut send or OSH cut. Both can bend and are fairly priced.

Nah, I'm in Ireland. If something like that was available to me I'd be all over it.

[Davidk]

https://xometry.eu/en/ i used them in past for some small parts (not car related)

[Alibro]

The new battery box is from 7:13

[chrskly]

https://xometry.eu/en/ i used them in past for some small parts (not car related)

Ooh, very interesting. How did you find them price-wise?

[chrskly]

The new battery box is from 7:13

You make it look easy I think I'll give this a go for the rear box.

I also didn't realise that you did a video series. Now I have loads more stuff to add to the queue

[Alibro]

You make it look easy I think I'll give this a go for the rear box.

I also didn't realise that you did a video series. Now I have loads more stuff to add to the queue

Good luck with that, Damien wishes he could be as boring as me.

The boxes worked out great, strong enough but much lighter and a fraction of the time to build.

[chrskly]

I put the brake pedal back in so I could figure out where to position the accellerator. Here's a little video of testing it out.

https://peertube.chrskly.net/w/9iMg2LQkj2bPKLHWRrhMwJ

I've also mounted the mid-pack disconnect in the lid of the front battery box.

I still need to cover up the fuse bulge.

Also did some futzing with the HVJB.

[chrskly]

Can I interest anyone in an over-engineered tail light?

[Alibro]

Am I the only one that dislikes flashy lights?
Bah humbug!

[chrskly]

Am I the only one that dislikes flashy lights?
Bah humbug!

I get it. I can't stand the unibrow headlights a lot of new cars are coming with!

[chrskly]

Been working away. Doing a quicky update to bring things up to date.

Roadworthiness

• Had the automotive engineer out to look at what I'm doing to make sure I'm not going down the wrong path. No issues so forging ahead

Brakes

• Wired up the iBooster up and tested it - seems to be working OK

• Made up some brackets to mount it

• Made up a bracket to attach the proportioning valve to the side of the iBooster

• Plumbed up new lines

Still to do

• Need a few p-clips here and there

• Paint up the new parts

• Make a pushrod extension

Motor

• Made up the rear mount for the motor. Used the original cross member. Cut a couple of rectangles out of a rubber mat. Bit of plate and some bolts holds everything together.

• The handbrake mechanism sits on the crossmember. I had to cut the bracket that holds it off to move it down a bit to make space for the output flange on the motor.

Propshaft

• With the motor position finalised I measured everything.

• Took the flange off the diff (oil everywhere) and the rubber damper off the motor and brought them down to a nearby driveshaft shop. Waiting on them to make up a prop for me.

Wheels

• Got some fancy new wheels and tyres

Inverter

• Made up the three arms to hold the inverter in place

• Realised that one was hard mounted and the others were soft mounted so will need to re-do the front one.

• Quick test fit of the HV cables

• Printed out all of the bits for the inverter in PETG

Coolant

• Bought a rad

• Started planning out the location/routing of the coolant loop

What's next

• Make up an arm to hold the front of the battery box in the engine bay

• Start installing some basic 12V stuff - fuse/relay boxes, main relay, 12V battery

• Finish the front battery box - needs the HV socket, LV socket, paint, lifting eyes

• Sandblast the old fuel tank so I can start mounting some of the charging stuff in there

• Figure out how to mount the accelerator pedal

• Buy a windscreen